Amp Mods · Global Master Volume Mod Kit Deluxe and Deville
Hot Rod Deluxe/Deville Global Master Volume Modification
Thanks for purchasing the Hot Rod DeVille/Deluxe Global Master Volume Modification Kit.
Optional Tools/Supplies:
- 9/16” nut driver or socket wrench.
- 1/2” nut driver or socket wrench.
- Fine point Sharpie or similar permanent marker.
- Masking Tape
Skills required:
- Basic soldering skills .
- Basic knowledge of electronics.
- The Ability to follow instructions.
Resistor Guide
- BLACK 0 K
- BROWN 1 N
- RED 2 R
- ORANGE 3 O
- YELLOW 4 Y
- GREEN 5 G
- BLUE 6 B
- VIOLET 7 V
- GREY 8 E
- WHITE 9 W
Parts
- WIMA Cap 10mm .022 (Code 223)
- Resistor 1/2W 56K
- Resistor 1/2W 220K
- Wire 8 inch × 2
- 100k Audio Pot 100kA
- 5 Watt Resistor (To Safely Drain Filter Capacitors)
Tools
- Temperature Controlled Soldering Iron and Solder
- Solder Sucker and or de-soldering braid
- Multi-Meter Capable of reading 500V DC
- Phillips Screwdriver
- Pliers with insulated handle
- Wire Cutters
- Safety Goggles
- Alligator Leads
1
Step 1
- WARNING: Performing these modifications WILL void the warranty on your amplifier. Working on amps can be deadly if you do not take proper precautions. Follow these instructions very carefully. If you are at all unsure of your ability to perform these modifications STOP and take your amp to a professional to be modified. You can also send your amp to me for modification.
- No Warranty: This kit and the instructions included do not include any warranty of any kind. The modifications to your amplifier are at your own risk and you agree to completely hold harmless the seller of this kit against any and all claims. Tube amplifiers contain parts that operate at very high temperatures and deadly voltages. If you are not sure of your abilities to perform these modifications then do not perform them.
2
Prep the Amp
- Instructions: Follow these instructions to the letter.
- It’s a good idea to have all the parts and tools you will need laid out before starting in a well lit area.
- Unplug the Amp and put on your safety goggles.
3
Step 3
- Remove the chicken head control knobs by loosening the set screws. Remove the nuts and washers holding the potentiometers and jacks on the top panel.
4
Step 4
- Remove the screws holding on the back panel and remove the panel. If the back panel does not come off easily you can loosen the chassis screws on the side of the amp about a half turn each.
5
Step 5
- Drain the Filter Caps: The filter caps on your amp may be drained already but you must follow these steps to insure that any deadly voltage is removed from the amp before you begin work. Test the voltage across the filter caps. Set your multi meter to DC and measure the voltage across the positive and negative side of any of the filter caps. If the voltage reads higher than 10 volts, then you need to drain the caps.
6
Step 6
- Using the insulated pliers to hold the included 5 watt power resistor touch one lead of the resistor to the negative side of the filter cap and the other to the positive side, leave the leads in contact with the power resistor for 30 seconds and measure again. Keep repeating this step until the voltage reads below 10V. Capacitors can recharge even when the amp is not plugged in!!! After the filter caps are drained take an alligator lead and clip one end to the positive lead of the filter cap and the other end to the chassis and leave it there until you are done with your work. This will prevent the filter caps from re-charging.
7
Step 7
- Clip all of the wire ties.
8
Step 8
- Remove all the nuts from the pots.
9
Step 9
- Unplug all the power and output transformer leads by pulling firmly with steady pressure gently rocking the lead terminal from side to side. As you remove each lead mark the wire with masking tape and a Sharpie so you will know where to plug it back in when you are putting the amp back together. I just mark the terminal number on the lead.
10
Step 10
- Remove all circuit board standoff screws.
11
Expose the circuit board
- Pull gently on the board to make sure that it is not stuck to any of the standoffs that were holding the circuit board screws.
12
Step 12
- Press the wires from the output transformer and reverb as far away from the board and as close to the chassis as possible. The board needs to come down toward the bottom of the amp before the pots will clear the top of the chassis as shown.
13
Step 13
- Using gentle pressure on the top of the circuit board press the board down making sure it is not getting hung up on any wires until all the pots have cleared the top of the chassis then pull the board to you to expose the underside. DO NOT PUT PRESSURE ON ANY COMPONENTS INCLUDING THE FILTER CAPS WHEN MOVING THE BOARD.
14
Removing the Old Components
- Be careful that your soldering iron is not too hot. The solder pads on the PCB are prone to curling and separating from the PCB, so remove the components with care, never using force. It is best to clip the component leads on the front of the PCB then remove the remainder of the lead and solder from the back side carefully with a solder sucker and de-soldering braid.
- Remove the follow components and use the diagram below as a guide.
- Blue components are removed
- Yellow components will be changed
- Green highlights will be jumped
15
Step 15
- Remove the capacitors at C3, C9, C10, C11, C23
16
Step 16
- Remove the Relay at K2
17
Step 17
- Remove the resistors at R19, R20, R21, R22, R24, R25, R44, R45, R52
18
Step 18
- Remove transistor at Q2
19
Step 19
- Remove the COAX cable that runs from the master volume pot to the left side of C10
20
Step 20
- Remove the Master Volume pot at R26
21
Step 21
- CAUTION: The circuit board is very fragile and the solder pads can easily become separated from the circuit board if extreme care is not used. Carefully examine each solder pad after removing the component to make sure the solder pad is intact. If the solder pad is damaged you will need to carefully scrape away the solder mask of the trace next to the hole, bend the lead to the trace and solder directly to the trace. Remember to always check continuity with your multi-meter to insure that you have a good connection between components.
22
Adding the New Components
- Install the 100kA pot into R26
23
Step 23
- Install the 56k resistor at R44
- 220k
- .022uf
- 56k
24
Step 24
- Install the 220k resistor at R52
25
Step 25
- Install the .022 WIMA cap at C23
26
Step 26
- Jump each R19 and Jump R21 using a clipped lead
- JUMP
- JUMP
27
Step 27
- Jump the bottom hole of R22 to the bottom hole of R20 using a clipped lead.
28
Step 28
- Finally, Wire WJ12 below the master volume pot to the 2nd hole down from the removed relay at K2, as well as the hole closest to the top of the board of R45 to the 3rd hole down from the removed relay at K2 (as pictured below).
- Master Volume Pot
- From WJ12
- From R45
29
Putting the Amp Back Together
- Make sure that you have clipped all the excess leads from the solder side of the board and that all your new solder joints are secure before continuing.
30
Step 30
- Carefully put the PCB back into place making sure that the pots, switches, and input jack all line up with the control panel.
31
Step 31
- Replace all of the PCB mounting screws.
32
Step 32
- Re-install the small PCB that holds the tubes.
33
Step 33
- Make sure all the ribbon cables have a smooth path with no kinks or sharp turns in the cable.
34
Step 34
- Dress the Transformer leads!!! Poor lead dress is a large part of the noise in an amp. Instead of using a new cable tie to put the wires back like we found them we are going to use standard wiring techniques for proper tube amp design. Twist the green heater wires and position as shown. All other lead pairs should cross each other at 90 degree angles to avoid noise, hum, and oscillation.
35
Step 35
- Re-install all the washers for the pots and jacks use the isolation washers on the input jacks as shown. Do not over tighten the jacks for the effects loop or footswitch.
36
Step 36
- Make sure all the ribbon cables have a smooth path with no kinks or sharp turns in the cable.
37
Step 37
- Glue ALL the caps to the board as well as the lead wire for the reverb. You can omit this step if you want but securing all the caps to the board will decrease the likely hood that they will get shaken loose in travel or by vibrations from the speaker.
38
Step 38
- Plug the speaker back into the speaker jack.
39
Step 39
- Re-install the control knobs and install the washer and nut on the new input jack.
40
Step 40
- DOUBLE CHECK ALL YOUR WORK.
41
Step 41
- Replace the back panel and make sure to tighten the chassis screws if you loosened them.
Finishing up
ENJOY YOUR NEW AMP